project feasibility report - welcome to...

PROJECT FEASIBILITY

REPORT

FOR OBTAINING

PRIOR ENVIRONMENT CLEARANCE

For

PROPOSED CHEMICAL (POLYURETHANE

FOAM) MANUFACTURING UNIT

From

M/s. RADHEY FOAM PVT. LTD.

LOCATED AT:

Block No. 176, Vill: Kadodara, Tal: Palsana, Dis. Surat, State: Gujarat.

mailto:[email protected]

INDEX

CHAPTER

NO. TITLE PAGE NO.

1. Executive Summary 1

2. Introduction of Project / Background Information 2

3. Project Description 3

4. Site Analysis 8

5. Planning Brief 10

6. Proposed Infrastructure 12

7. Rehabilitation and Resettlement (R & R) Plan 13

8. Project Schedule & Cost Estimates 13

9. Analysis of Proposal 14

PRE-FEASIBILITY REPORT M/s. RADHEY FOAM PVT. LTD.

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1. EXECUTIVE SUMMARY

M/s. Radhey Foam Pvt. Ltd. has proposed to manufacture the product Polyurethane

Foam at Block No. 176, Vill. Kadodara, Tal: Palsana, Dis. Surat, State: Gujarat.

Basically, the proposed location is not falling in GIDC & unit has proposed manufacturing

of synthetic organic chemical activity. Distance of interstate boundary is 72.84 Km from

project site. Therefore, project falls under category A of schedule 5(f), as per the EIA

Notification, September 2006. Therefore, it requires prior Environment Clearance.

There is no forest/wild life sanctuary/eco sensitive area present within 10 Km area from

the project site.

The proposed unit will be developed in an industrial park. The land is already Non-

Agriculture. The Proposed project activity will be developed as per plan lay out shown in

Annexure – 2 of EC Application in industrial park.

The Proposed project activity will be carried out in existing Industrial shed. No additional

construction activity will carry out.

For, Electric power requirement: Unit will apply for electric connection of 50 KVA to

DGVCL. One D. G Set of capacity 250 KVA will be installed which will be used in case of

power failure.

For proposed activity, water required for domestic & industrial purpose will be sourced

from Bore well. Domestic effluent will be disposed in to Septic tank/Soak pit system. No

Industrial effluent will be generated from process.

No solid hazardous waste will be generated from manufacturing process. Hazardous

waste generated from the other industrial activity will be stored in a separate hazardous

waste storage area and then it will be disposed by selling to register re-cyclers/re-

refiners/reused.

Proper safety measures will be undertaken during storage, handling and use of hazardous

substance. Fire hydrants, Hose reel & Portable Fire Extinguishers will be provided at key

location.

Total area of project site is 11,100.0 m2. The proposed green belt area is 4415 m2.

During operation phase 35 people (30 men + 5 women) will be required.


[2]

2. INTRODUCTION OF PROJECT / BACKGROUND INFORMATION

2.1 IDENTIFICATION OF PROJECT AND PROJECT PROPONENT

Unit is located in Village Kadodara. The Kadodara is a Village in Palsana Taluka in Surat

District of Gujarat State, India. It is located 13.40 KM towards East from District head

quarters Surat, 11 KM from Kamrej & 230 KM from State capital Gandhinagar.

List of product to be manufactured is as under;

LIST OF PRODUCT

Sr. No.

Name of Product Quantity

(MT/Month)

1. Polyurethane Foam 300

PROJECT PROPONENT

M/s. Radhey Foam Pvt. Ltd. is a Private Limited Firm.

Mr. Kishorbhai Shanghani is one of the Directors of the company.

2.2 NATURE OF THE PROJECT

M/s. Radhey Foam Pvt. Ltd. is a small scale unit. It falls under the category of

synthetic organic chemical (Polyurethane Foam) industry.

2.3 NEED FOR THE PROJECT

M/s. Radhey Foam Pvt. Ltd. will be supplying polyurethane foam to several industries.

There are numerous uses of polyurethane foams such as packaging, acoustic

insulation, filtration, sponges, seals, padding in sports shoes, paint rollers, medical

applications, textiles, furniture, Bedding and many other varied applications. Due to

increase in both national & local market demand, unit proposes to the production of

Polyurethane foam.

2.4 EMPLOYMENT GENERATION (DIRECT & INDIRECT) DUE TO THE

PROJECT

Due to the project, employment will be increased. The unit will hire local people from the

nearby villages.

People will get direct & indirect employment due to the project activity. Unit will hire 35

employees- (30 men + 5 women)


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3. PROJECT DESCRIPTION

3.1 TYPE OF PROJECT

The unit has proposed to manufacture synthetic organic chemical – Polyurethane foam.

3.2 LOCATION

The site is located at about 21°10’01.97” N latitude and 72°57'31.46"E longitude.

LOCATION OF THE PROJECT

3.3 DETAILS OF ALTERNATE SITES

Proposed project is identically located in an industrial park having all adequate

infrastructure available. Therefore, no alternate site is considered for the proposed project.

3.4 SIZE / MAGNITUDE OF OPERATION

Proposed project activity will be carried out on Block No. 176, Village: Kadodara, Tal:

Palsana, Dist: Surat in RCC G-floor shed.


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3.5 PROJECT DESCRIPTION WITH PROCESS DETAILS

Manufacturing Process Description:

The raw materials n-Butyl Alcohol (Polyol), TDI (Toluene Di Isocyanate), Catalysts (Silicon,

SO, DMEA/MI), Filler (CaOH) and MECL (Methylene Chloride) are pumped from their own

storage tank in required proportions to a common mixing chamber where the materials are

mixed at high speed and flows as cream on to a conveyor.

While passing on the conveyor the cream expands to full height to make foam blocks.

Continuous foamed blocks are cut into required block sizes by the block cutter and the cut

blocks are left for sufficient time in open atmosphere for curing.

The blocks are further cut into sheets of required size by horizontal and/or vertical cutting

machines and are packed for dispatch or cut into rolls by peeling machine.

Manufacturing Process Flow Diagram


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REACTION CHEMISTRY

MATERIAL BALANCE

3.6 RAW MATERIAL WITH REQUIRED QUANTITY, SOURCE, MARKETING AREA OF FINAL PRODUCTS, MODE OF TRANSPORT OF RAW MATERIAL AND FINISHED PRODUCT

For Product and Raw material with required quantity, please refer Annexure – 4 of EC

application. For source of raw materials, supply of final product, their handling-

management & mode of transportation, please refer Annexure – 7 of EC application.

3.7 RESOURCE OPTIMIZATION / RECYCLING AND REUSE

Used oil generates from operation of DG Set will be reused as lubricant for the machinery.

3.8 AVAILABILITY OF WATER, ITS SOURCE, ENERGY / POWER REQUIREMENT AND SOURCE

Energy / Power Requirement & Its Source

Electric power requirement for proposed project is 50 KVA, which will be procured from

Dakshin Gujarat Vidyut Company Ltd. (DGVCL).

One D. G Set of capacity 250 KVA will be installed which will be used in case of power

failure.


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Water Availability & Its Source

Source of Water: Bore well (Water Depth: 20 – 25 Mtr.)

WATER CONSUMPTION

Sr. No.

Category Water

Consumption (KL/day)

1. Domestic 11.0

2. Gardening 12.0

i. TOTAL 23.0

1. Process 3.0

2. Chilling Plant 0.3

ii. TOTAL 3.3

GRAND TOTAL (i + ii) 26.3

3.9 QUANTITY OF WASTES TO BE GENERATED (LIQUID AND SOLID) AND SCHEME FOR THEIR MANAGEMENT / DISPOSAL

(A) Quantity of Liquid Waste to be Generated & Its Management / Disposal:

WASTEWATER GENERATION

Sr. No.

Category Water

Generation (KL/day)

1. Domestic 10.0

2. Gardening NIL

i. TOTAL 10.0

1. Process NIL

2. Chilling Plant NIL

ii. TOTAL NIL

GRAND TOTAL (i + ii) 10.0

Disposal of Wastewater:

1. Domestic effluent will be disposed in to Septic tank / Soak pit system.

2. The quantity of trade effluent generated will be NIL

(B) Quantity of Solid Waste to be Generated & Its Management / Disposal:

No Hazardous waste will be generated from the process. Hazardous waste generated

from other industrial activity will be stored in a separate hazardous waste storage area

and it will be disposed by selling to the register re-cyclers/re-finer/reused.


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Sr. No.

Type of Waste Category Source of

Generation

Quantity Facility

Total

01. Used Oil 5.1 D. G Set 0.045

MT/Year

Collection, Storage, Transportation, Disposal by selling to Registered

Re-refiners, approved by GPCB/CPCB or reused as lubricant

for machinery within the factory.

02. Discarded

Containers/Bags 33.3 --

60 Nos./Year


recycler approved by GPCB/CPCB

03. Waste Foam

(Product cutting waste)

-- Process -- Collection & reuse again in process

04. Carbon Waste 35.3 APCM 2

Kg/Month


recycler approved by GPCB/CPCB

The municipal solid wastes generated during operation phase will be disposed to bin of

Industrial park.

3.10 SCHEMATIC REPRESENTATIONS OF THE FEASIBILITY DRAWING WHICH GIVE INFORMATION OF EIA PURPOSE

SCHEMATIC REPRESENTATIONS OF PROJECT

Location of Project

Activity

Outside GIDC/Notified area

Thus, project falls under category A

Production of Polyurethane Foam – Synthetic Organic Chemical activity

Thus, falls under schedule 5(f)

Thus, overall project require EIA as per MoEF notification.


[8]

4. SITE ANALYSIS

4.1 CONNECTIVITY

The project site is well connected with all infrastructures like National Highway, Railway,

Airport, telephone, internet, fax, post, etc.

Nearest town Kadodara is located 0.54 Km in N direction, Kamrej is located 11.0 Km in N

direction from the project site.

Nearest city, district headquarters Surat is located 13.40 Km in W direction from the project

site.

National Highway No. 8 is located 0.32 Km in E direction & National Highway No. 6 is located 0.58

Km in N direction from the project site.

Nearest railway station Udhna is located 10.46 km in W direction & Bardoli railway station is

located 15.68 in SE Direction from the project site.

Nearest airport Surat is located 23 km in SW direction from the project site.

4.2 LAND FORM, LAND USE AND LAND OWNERSHIP

The Proposed project activity will be carried out in existing Industrial shed. No additional

construction activity will carry out. The proposed project will not cause any permanent or temporary

change to land use.

LAND AREA BIFURCATION

Sr. No.

Title Area (m2)

GROUND FLOOR

1. Finished product section (Cutting, Packing & Storage)

932.4

2. Raw Material Storage Area 337.0

3. D. G Set 5.0

4. Hazardous Waste Storage Area 10.0

5. Office 30.0

6. Green belt area

Within premises 4415.0

7. Parking Area 97.5

8. Open Space 2698.1

9. Product Curing Area 932.0

10. Process Area 189.0


12. Road area within premises 1450

TOTAL AREA 11,100.0

4.3 TOPOGRAPHY

The project area is plain and flat surface with elevation 21 m above MSL. However, in the

NE part, the elevation is in the range of 21 – 24 m above MSL & in the SW part, the

elevation is in the range of 18 – 25 m above MSL. The general slope of the area is from


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NE to SW. In the buffer zone towards NE, E & SE, the elevation rises to 24 m and above

MSL & towards S, SW & W the elevation descend to 18 m above MSL.

4.4 EXISTING LAND USE PATTERN, SHORTEST DISTANCE FROM THE PERIPHERY OF THE PROJECT TO PERIPHERY OF THE FOREST, NATIONAL PARK, WILD LIFE SANCTUARY, ECO SENSITIVE AREA, WATER BODIES (DISTANCE FROM THE HFL OF THE RIVER), CRZ

The land is non agriculture. The project site is located in an industrial park. There shall be

no forest, wild life sanctuary, eco sensitive area within 10 km from the project site. The

details of water bodies and nearest park are mentioned below:

Tapi River is 12.81 Km in N direction.

Mithi Khadi is 1Km in N direction

Arabian Sea is 29.17 Km in WSW direction.

Vansda National Park is 79.82 Km in SE direction.

Purna Wildlife Sanctuary is 82.22 Km in SE direction.

Dandi Eco-Sensitive Zone is 36.85 Km in SW Direction.

Canal: 4.73 Km in N direction from the project site.

4.5 SOIL CLASSIFICATION

Soil in the study area is primarily black & Silty clay in nature.

4.6 SOCIAL INFRASTRUCTURE AVAILABLE

The proposed project is located in an industrial park. Industrial Park authority will provide

power supply, water supply, pucca road, telephone & other communication network &

drainage network in the area.

Skilled & unskilled manpower are available within area. Ambulance and emergency fire &

medical service available round the clock.


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5. PLANING BRIEF

5.1 PLANNING CONCEPT

The unit has proposed to manufacture Polyurethane Foam. Proposed project activity will

be carried out at B. No. 176, Village: Kadodara, Tal: Palsana, Dist: Surat, Gujarat. The

Proposed project activity will be carried out in existing Industrial shed. No additional

construction activity will carry out.

All the basic facilities like tap water, sanitation & drinking water, canteen & First aid box

will be provided within premises.

The project site is well connected with the road, railway and airport. Finished products and

raw materials will be transported through road. There is no requirement for the

development of other road or railway.

5.2 POPULATION PROJECTION

During operation phase 35 people-Direct (30 men + 5 women), 35 employees

5.3 LAND USE PLANNING

The breakup of the land area is mentioned in the below table:

LAND AREA BIFURCATION

Sr. No.

Title Area (m2)

GROUND FLOOR

1. Finished product section (Cutting, Packing & Storage)

932.4

2. Raw Material Storage Area 337.0

3. D. G Set 5.0

4. Hazardous Waste Storage Area 10.0

5. Office 30.0

6. Green belt area

Within premises 4415.0

7. Parking Area 97.5

8. Open Space 2698.1

9. Product Curing Area 932.0

10. Process Area 189.0


12. Road area within premises 1450

TOTAL AREA 11,100.0


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5.4 ASSESSMENT OF INFRASTRUCTURE DEMAND (PHYSICAL & SOCIAL)

The project is located in an industrial Park. Industrial park Authority will provide power

supply, water supply, pucca road, telephone & other communication network & drainage

network in the area.

Skilled & unskilled manpower are available within area. Ambulance and emergency fire &

medical service available round the clock.

Local people will be hired for new products and they will be trained within unit. Thus, no

social infrastructure will require.

5.5 AMENITIES / FACILITIES

All the basic facilities like tap water, sanitation & drinking water, canteen will be provided

within premises.

First aid box, free medicines & doctor service (on call basis) will be provided.

Adequate PPE’s will be provided to all workers.


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6. PROPOSED INFRASTRUCTURE

1. Industrial Area Total Area – 11,100 m2

2. Residential Area Residential area is located 700 m in NE direction.

3. Green Belt Proposed – 4415.0 m2

4. Social Infrastructure Social infrastructure available within 10-15 km from project

site.

5. Connectivity National Highway No. 8 is located 0.32 Km in E direction &

National Highway No. 6 is located 0.58 Km in N direction.

Nearest railway station – Udhna railway station is located

10.46 Km in W direction & Bardoli railway station is located

15.68 Km in SE Direction.

Nearest Airport – Surat Airport 23.0 Km in SW direction.

6. Drinking Water Management Source of water for domestic & industrial purpose is from

Bore Well.

7. Sewerage System Domestic effluent will be disposed in to existing Septic

tank / Soak pit system.

No Industrial effluent will be generated/ discharged.

8. Industrial Waste Management Discarded Containers/Bags – Collection, Storage,

Decontamination and Disposal by selling to registered re-

cyclers approved by GPCB/CPCB

Used Oil – Collection, Storage, Transportation, Disposal by

selling to Registered Re-refiners approved by

GPCB/CPCB.

Waste Foam (Product cutting waste) – Collection & Reuse

in Manufacturing process again.

9. Solid Waste Management MSW disposed to bin of nearby Palsana Nagarpalika.

10. Power Requirement & Supply /

Source

Source: Dakshin Gujarat Vidyut Company Ltd.

Proposed power requirement: 50 KVA


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7. REHABILITATION AND RESETTLEMENT (R & R) PLAN

The project is located within an Industrial park therefore no Rehabilitation & Resettlement

(R & R) plan is involved in proposed project.

8. PROJECT SCHEDULE & COST ESTIMATES

8.1 LIKELY DATE TO START OF CONSTRUCTION AND LIKELY DATE OF

COMPLETION

Production of proposed product will be started after getting Environment Clearance

(SEAC) and CTE/CC&A from the GPCB.

8.2 PROJECT COST ESTIMATION

Estimated cost for the proposed project is as under;

Details Description Approximate

Recurring Cost Per Annum (Rs. in Lacs)

Approximate Capital Cost (Rs. in Lacs)

Land Plot is owned by the project

proponent

-- 25.00

Building RCC G floor 1.00 42.00

Plant & Machinery New machineries required for the

proposed project.

2.00 122.00

Green Belt

Development

Proposed green belt area will be

developed 0.50 3.00

CSR Activity Donate computer to nearby

village school -- 3.00

TOTAL - 3.50 195.00


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9. ANALYSIS OF PROPOSAL

9.1 FINANCIAL AND SOCIAL BENEFITS WITH SPECIAL EMPHASIS ON THE

BENEFIT TO THE LOCAL PEOPLE INCLUDING TRIBAL POPULATION, IF

ANY, IN THE AREA

Project is located in an industrial park. Therefore, No R & R plan involved in proposed

project.

Due to proposed project it is expected that employment will increase for people who reside

nearby project area. Approx. 30 men & 5 women will get employment directly.

Due to increase in raw material and product transportation activity, indirect employment

will generate.

As local people will get job, quality of living will be increase.

Due to green belt development, aesthetic value of local environment will improve.

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